Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B43—WRITING OR DRAWING IMPLEMENTS; BUREAU ACCESSORIES
  • B43M—BUREAU ACCESSORIES NOT OTHERWISE PROVIDED FOR
  • B43M3/00—Devices for inserting documents into envelopes
  • B43M3/04—Devices for inserting documents into envelopes automatic
  • B43M3/045—Devices for inserting documents into envelopes automatic for envelopes with only one flap
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B43—WRITING OR DRAWING IMPLEMENTS; BUREAU ACCESSORIES
  • B43M—BUREAU ACCESSORIES NOT OTHERWISE PROVIDED FOR
  • B43M3/00—Devices for inserting documents into envelopes
  • B43M3/04—Devices for inserting documents into envelopes automatic
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
  • B31B—MAKING CONTAINERS OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
  • B31B70/00—Making flexible containers, e.g. envelopes or bags
  • B31B70/26—Folding sheets, blanks or webs
  • B31B70/262—Folding sheets, blanks or webs involving longitudinally folding, i.e. along a line parallel to the direction of movement
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B43—WRITING OR DRAWING IMPLEMENTS; BUREAU ACCESSORIES
  • B43M—BUREAU ACCESSORIES NOT OTHERWISE PROVIDED FOR
  • B43M5/00—Devices for closing envelopes
  • B43M5/04—Devices for closing envelopes automatic
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
  • B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
  • B65B11/00—Wrapping, e.g. partially or wholly enclosing, articles or quantities of material, in strips, sheets or blanks, of flexible material
  • B65B11/06—Wrapping articles, or quantities of material, by conveying wrapper and contents in common defined paths
  • B65B11/18—Wrapping articles, or quantities of material, by conveying wrapper and contents in common defined paths in two or more straight paths
  • B65B11/20—Wrapping articles, or quantities of material, by conveying wrapper and contents in common defined paths in two or more straight paths to fold the wrappers in tubular form about contents
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
  • B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
  • B65B25/00—Packaging other articles presenting special problems
  • B65B25/14—Packaging paper or like sheets, envelopes, or newspapers, in flat, folded, or rolled form
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
  • B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
  • B65H45/00—Folding thin material
  • B65H45/12—Folding articles or webs with application of pressure to define or form crease lines
  • B65H45/14—Buckling folders
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
  • B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
  • B65H2701/00—Handled material; Storage means
  • B65H2701/10—Handled articles or webs
  • B65H2701/19—Specific article or web
  • B65H2701/1916—Envelopes and articles of mail

Definitions

• the subject matter described herein relates generally to creating mailpieces in an automated manner. More particularly, the subject matter described herein relates to creating mailpieces in an automated manner using a buckle folder without folding printed material to be inserted within each mailpiece.
• these pre-assembled envelopes generally are stopped at one or more specified positions so that they can be opened (e.g., by applying a vacuum or by other mechanical devices) for insertion of the printed insert materials therein.
• this approach requires that the envelopes be pre-assembled and delivered to the inserting machine in regular intervals to be manually loaded into the inserting machine by an operator. Because the envelopes must come to a stop within the inserting machine during processing, such conventional inserters suffer from relatively frequent paper jams and significant mailpiece damage.
• the subject matter described herein relates to creating mailpieces in an automated fashion from cut paper or a continuous web of paper to form the envelopes of each mailpiece around printed insert material that is positioned on the envelope during creation of the mailpiece.
• a system configured to fold an envelope sheet around one or more insert sheets to create a mailpiece.
• the system comprises: an insert transport path configured to transport the one or more insert sheets to a merge region; a primary transport path configured to transport the envelope sheet to the merge region; an insert stager that is connected to the insert transport path and arranged proximate to the primary transport path at the merge region, the insert stager being configured to receive the one or more insert sheets from the insert transport path in a form of an insert stack, hold the insert stack until the envelope sheet is detected at a first position on the primary transport path, and to dispense the insert stack onto the envelope sheet as the envelope sheet is being transported along the primary transport path, the insert stack being dispensed from the insert stager at substantially a same speed as a speed at which the envelope sheet moves along the primary transport path; an adhesive dispensing system configured to seal sides of the envelope by applying glue along lateral edges of a back side portion of the envelope sheet as the envelope sheet is fed into a buckle folder;
• a method of folding an envelope sheet around one or more insert sheets to create a mailpiece comprises: forming an insert stack from the one or more insert sheets; transporting the insert stack to a merge region along an insert transport path; transporting the envelope sheet to the merge region along a primary transport path; receiving the insert stack at an insert stager that is connected to the insert transport path and arranged proximate to the primary transport; holding the insert stack within the insert stager; detecting the envelope sheet at a first position on the primary path; dispensing the insert stack onto the envelope sheet as the envelope sheet is transported along the primary transport path, wherein the insert stack is dispensed at substantially a same speed as a speed at which the envelope sheet moves along the primary transport path; folding the envelope sheet around the insert stack to form an unsealed envelope for the mailpiece, wherein the unsealed envelope comprises, on a first side of the insert stack, a back side of the mailpiece and, on a second side of the insert stack opposite the first side
• a device configured to sequentially receive and dispense one or more insert sheets as an insert stack onto an adjacent envelope sheet.
• the device comprises: a holding slot for the insert stack; a stop gate disposed at an exit of the holding slot; and a mechanical linkage system configured to produce first and second motion profiles from a single input, the mechanical linkage system comprising: a motor configured to generate a locomotive force, wherein the locomotive force is the single input; a crank arm that is connected to the motor; a coupler linkage coupled, at a first end, to the crank arm via a coupler bearing and, at a second end, to a pivot bearing; a first linkage subassembly rotatably connected, at a first end, to the coupler linkage at the pivot bearing and comprising a stop gate arranged at a distal end of the first linkage subassembly, the single input being transmitted to the first linkage subassembly through the pivot bearing to generate the first motion profile,
• a system configured to create a mailpiece with an external envelope folded around one or more insert materials.
• the system comprises: one or more insert feeders configured to dispense one or more insert sheets onto an insert transport plate, wherein the one or more insert sheets from each insert feeder are stacked sequentially on top of each other to form an insert stack; an insert assembly transport belt configured to transport the insert stack on top of the insert transport plate; an envelope sheet feeder configured to dispense an envelope sheet onto an envelope transport plate; an envelope conveyor configured to transport the envelope sheet along the envelope transport plate by an envelope conveyor belt, wherein a speed of the insert assembly transport belt is different from a speed of the envelope conveyor belt; an insert stager located adjacent to the envelope conveyor at a merge region, wherein the insert stager is configured to: receive the insert stack from the insert assembly transport belt; hold the insert stack until triggered by a merge optical sensor to dispense the insert stack; and dispense, at a same time as or after the merge optical sensor detects the envelope sheet at a dispensing
• the subject matter described in this specification may be implemented in hardware, software, firmware, or combinations of hardware, software and/or firmware.
• the subject matter described in this specification may be implemented using a non-transitory computer readable medium storing computer executable instructions that when executed by one or more processors of a computer cause the computer to perform operations.
• Computer readable media suitable for implementing the subject matter described in this specification include non-transitory computer-readable media, such as disk memory devices, chip memory devices, programmable logic devices, random access memory (RAM), read only memory (ROM), optical read/write memory, cache memory, magnetic read/write memory, flash memory, and application specific integrated circuits.
• a computer readable medium that implements the subject matter described in this specification may be located on a single device or computing platform or may be distributed across multiple devices or computing platforms.
• FIG. 1 For a more complete understanding of the presently disclosed subject matter, reference is now made to the following figures (“FIGS.”), in which:
• FIG. 1 is a schematic illustration of the components of an example embodiment of a system configured to create a mailpiece with an external envelope folded around one or more inserts dispensed on the unfolded envelope during formation of the mailpiece;
• FIG. 2 is a perspective view of an example embodiment of the envelope sheet feeder of the system of FIG. 1 ;
• FIG. 3 is a perspective view of a portion of an example embodiment of the system of FIG. 1 , including an example embodiment of the envelope and insert merge region;
• FIGS. 4A through 4D are various perspective views of the insert stager illustrated in FIG. 3;
• FIGS. 4E through 4G are side views of the mechanical linkage system that controls the output of the insert stager;
• FIG. 6 is a perspective view of an envelope sheet and one or more inserts entering the adhesive applicator unit and the buckle folder of FIG. 1 , with the insert stager omitted for clarity;
• FIG. 7 is a perspective view of the envelope sheet being diverted into the buckle folder of the system of FIG. 1 ;
• FIG. 8 is a perspective view of the envelope sheet as the envelope sheet is formed into an envelope by the buckle folder and is drawn underneath the fold plate by a set of transport rollers;
• FIG. 9 is a second perspective view of the envelope sheet in approximately the same position as is shown in FIG. 8, but including details about application of the adhesive to the envelope sheet during envelope formation;
• FIG. 10 is a side view of the envelope sheet passing underneath the fold plate of the buckle folder and into the adhesive rollers to seal the front and back of the envelope together;
• FIG. 11 is a perspective view of an example embodiment of a portion of the system of FIG. 1 , including the buckle folder, the right angle turn (RAT) unit, and the bottom edge justifier; and
• the terms“about,”“substantially,”“approximately,” and any other such synonymous terminology, when referring to a value, a degree, or an amount of a composition, mass, weight, temperature, time, volume, concentration, percentage, etc. is meant to encompass variations of, for example, ⁇ 20% in some embodiments, ⁇ 10% in some embodiments, ⁇ 5% in some embodiments, ⁇ 3% in some embodiments, ⁇ 2% in some embodiments, ⁇ 1 % in some embodiments, ⁇ 0.5% in some embodiments, and ⁇ 0.1 % in some embodiments from the specified amount, degree, or amount, as such variations would be known by those having ordinary skill in the art as being appropriate to construct and/or operate the disclosed devices and/or systems, perform the disclosed methods, and/or employ the disclosed compositions.
• the phrase“consisting of” excludes any element, step, or ingredient not specified in the claim.
• the phrase“consists of” appears in a clause of the body of a claim, rather than immediately following the preamble, it limits only the element set forth in that clause; other elements are not excluded from the claim as a whole.
• the term“and/or” when used in the context of a listing of entities refers to the entities being present singly or in combination.
• the phrase“A, B, C, and/or D” includes A, B, C, and D individually, but also includes any and all combinations and subcombinations of A, B, C, and D.
• FIG. 1 is a schematic diagram of a mailpiece inveloping system, generally designated 10, which is configured to generate at least one (e.g., a plurality) sealed envelope from a sheet of paper (or any suitable fibrous material), using a buckle folder so that each envelope contains one or more insert (e.g., “printed insert material) therein.
• the envelope sheet moves through system 10 at a substantially constant speed, including when the one or more insert is positioned on a designated area of the envelope sheet.
• insert transport path 1 is oriented along the direction of travel 20
• insert transport path 2 is oriented to be substantially along the insert direction of travel 21.
• directions of travel 20 and 21 can be parallel to each other, substantially parallel to each other, or at an angle relative to each other (e.g., 30°, 45°, 60° 75°, 90°, or 90° ⁇ 10°).
• insert feeder e.g., 30C
• two insert feeders e.g., two of 30A, 30B, and 30C are installed, or that more than three insert feeders (e.g., 30A, 30B, 30C, ... , 30N) can be installed in or along insert transport path 2.
• one, some, or even all of such a plurality of insert feeders can be selectively disabled (e.g., electronically by computer 100 or manually by a human operator) so that less than all of the insert feeders will deposit (e.g., eject) an insert stored therein on top of inserts deposited on insert transport path 2 by“upstream” insert feeders (e.g., 30A is“upstream” of both 30B and 30C, while 30B is“upstream” of 30C but“downstream” of 30A).
• “upstream” insert feeders e.g., 30A is“upstream” of both 30B and 30C, while 30B is“upstream” of 30C but“downstream” of 30A).
• an insert stack is created, with the first insert in the stack being deposited by the furthest “upstream” insert feeder that is active (e.g., 30A) for the mailpiece being assembled, and the subsequent inserts to be included in the insert stack being deposited in a sequential manner on top of an insert deposited by an immediately“upstream” active insert feeder.
• the furthest “upstream” insert feeder that is active e.g., 30A
• insert feeder 30A deposits the first insert onto insert transport path 2.
• the first insert then moves along insert transport path 2 to pass underneath, or otherwise adjacent to (e.g., beside), insert feeder 30B, which deposits a second insert on top of first insert, so as to at least partially cover the first insert.
• the first and second inserts then move along insert transport path 2 to pass underneath or otherwise adjacent to (e.g., beside), insert feeder 30C which deposits a third insert on top of first and second inserts, so as to at least partially cover the first insert, the second insert, or portions of both the first and second insert.
• the inserts In embodiments where a plurality of inserts (e.g., an insert stack) is to be included in an assembled mailpiece, it is possible for the inserts to be arranged in the insert stack in any order, without regard for the dimensions of the respective inserts in the insert stack.
• the first insert at the bottom of the insert stack is the largest (e.g., in width, height, or thickness) insert, with each insert subsequently deposited in the insert stack having the same or smaller dimensions than the immediately adjacent insert.
• the inserts can be arranged to provide a visually appealing “cascading” arrangement (e.g., where each insert is partially visible behind the insert which is arranged directly in front thereof) when the insert stack is front, rear, or side registered.
• the inserts are deposited one on top of each other along insert transport path 2, and are held, at least temporarily, in an insert stager 35 until triggered to be deposited (e.g., ejected) out of insert stager 35 and onto a designated portion of a substantially flat envelope sheet being transported underneath, beside, or otherwise adjacent to insert stager 35 as the envelope sheet moves, along primary transport path 1 , from envelope sheet feeder 25 into merge region 40, where the insert stack merges with the envelope sheet.
• the merged envelope sheet and insert stack move together in the direction of travel 20, with substantially no relative movement therebetween, into adhesive applicator region 45, where adhesive is applied along at least a portion of the sides of the envelope sheet.
• the merged envelope sheet and insert stack enter a buckle folder system 50, where the envelope is formed without any creasing or substantial bending of the insert stack.
• the merged envelope sheet and insert stack then enter the side adhesive sealer 55, where the adhesive applied to the envelope sheet in adhesive applicator region 45 is activated (e.g., by pressure) to sealingly form the envelope.
• a right angle turn (RAT) module 60 changes the direction of travel 20 of the partially formed envelope, without actually rotating the envelope, so that the envelope is then bottom edge registered by a bottom edge justifier 65.
• RAT module 60 allows for system 10 to occupy a more compact footprint where an operator can access the majority of the components therein from a single position, rather than having to traverse the length of system 10, thus allowing for faster error intervention and correction, reducing downtime of system 10.
• the envelope itself can be turned rather than having its direction of travel 20 changed.
• System 10 is configured to be controlled by a computer 100, using information obtained from a server 96.
• Computer is configured for control, either remote or local, by an operator by a user terminal 98.
• server 96 has a list of “jobs” in a queue, with the“jobs” being orders for mailpieces that need to be created.
• one or more of the“jobs” may direct an operator to change one or more setting or component of system 10 for the particular mailpiece assembly job to be performed. For example, where a unique invoice is to be included in each mailpiece, the operator may be instructed to place such invoices into one of the insert feeders 30A, 30B, and 30C for insertion into each of the mailpieces.
• the operational throughput (e.g., volume of mailpieces), errors, warnings, envelope sheet size, insert stack size, and any other operational parameters can be input by and/or displayed to an operator through user terminal 98 and transmitted to and/or from computer 100, so that when an error condition (e.g., a paper jam) is detected or an informational message (e.g., low paper) needs to be displayed, computer 100 can display such messages to the operator at user terminal 98, thus directing the operator to the specific location of the error or the location to which the informational message pertains for corrective action.
• System 10 operation and control may be configured, in some embodiments, to use PLC (Programmable Logic Controller) components and a control panel (e.g., a user input device) for system operation.
• PLC Programmable Logic Controller
• system 10 may be controlled by computer 100. In still other embodiments, system 10 may be controlled by some combination of the components described above (e.g., PLC components, a control panel, and/or computer 100).
• System 10 is configured to process and generate up to and including 15,000 mailpieces per hour. In some embodiments, system 10 can process and generate from as few as 1 ,000 and up to 20,000 mailpieces per hour.
• envelope sheets 310 are contained within an envelope sheet hopper 102.
• Envelope sheets 310 can be either plan paper stock or pre-printed with any suitable material (e.g., images and/or text).
• the plain paper stock can be advantageous in that there is no need to have pre-printed inventory, eliminating a common scenario where such pre-printed inventory becomes outdated (e.g., replaced with a new design) while in storage.
• Envelope sheets 310 are individually dispensed from envelope sheet hopper 102 by envelope sheet dispenser 104 and transported onto envelope conveyor 111 , which may be disposed on, or separate from, an envelope transport plate 110, by one or more feeder rollers 106.
• envelope sheets 310 are rear edge registered by one or more tabs 112 formed on or otherwise attached to one or more envelope conveyor belts 113. These tabs 112 push envelope sheets 310 along envelope conveyer 111.
• envelope sheets 310 have an envelope window 312 formed therein.
• envelope window 312 is covered by a glassine layer to protect the contents of the assembled mailpiece.
• Envelope window 312 allows for unique printed information on an insert visible within an assembled mailpiece to be externally visible, such as would be necessary for address information to be visible for delivery.
• a plurality of envelope windows 312 can be formed in envelope sheet 310, enabling, for example, a return address to be visible.
• envelope window 312 allows for unique mailings to be created based on insert contents and not based on unique printing on the outside of an assembled envelope.
• envelope sheet hopper 102 and envelope sheet dispenser 104 can be replaced with a paper dispenser and cutter 117, which is configured to form the envelope sheets 310 from a continuous web (e.g. roll) of paper that is cut to the proper size for a given assembled mailpiece.
• envelope window 312 is shown already formed into envelope sheet 310, it is possible in some embodiments for envelope window 312 to be formed in envelope sheet 310 “on demand” (e.g., during envelope assembly) by, for example, a laser cutting device or a die-cutting device. This can be especially useful where paper dispenser and cutter 117 is used, such that envelope sheets 310 are formed from a continuous web of paper, rather than from pre-cut paper stock, as is shown in FIG. 2.
• an insert feeder generally designated 30, is shown located vertically above envelope conveyor 111. While a single insert feeder 30 is shown, it is noted that a plurality of such insert feeders arranged sequentially is expressly contemplated (see, e.g., FIG. 1 ) and, in fact, at least one such“upstream” insert feeder (e.g., 30A or 30B) is present and active in the example embodiment shown in FIG. 3, as primary inserts 322 are moving underneath insert feeder 30 along insert transport path 2, such that insert feeder 30 deposits secondary insert 324 on top of primary insert 322 as primary insert 322 moves adjacent to (e.g., underneath) insert feeder 30.
• insert feeder 30 e.g., 30A or 30B
• all inserts including primary insert 322 and secondary insert 324, move at a constant speed along insert transport path 2 after being dispensed from a respective insert feeder 30 onto insert stack, generally designated 320.
• Insert stack 320 moves along insert transport path 2, being driven by insert assembly transport belt 230 and each of the inserts in insert stack 320 being rear edge registered by tabs 232 formed on or substantially fixedly attached to insert assembly transport belt 230.
• a first insert assembly deposits a primary insert 322 (e.g., a control insert) onto insert assembly transport belt 230, which is rear edge registered by tabs 232.
• a primary insert 322 e.g., a control insert
• a secondary insert 324 is inserted on top of primary insert 322, thus creating insert stack 320.
• one or more further inserts e.g., a tertiary insert, et seq.
• Each insert of insert stack 320 is rear edge registered by tabs 232.
• Such rear edge registering can further be provided by precisely timed depositing of the secondary (and further) inserts onto insert stack 320, as well as by normal operational vibration levels, which act to reduce relative friction between the inserts within insert stack 320.
• the inserts may be deposited from insert feeders 30 at a speed that is less than the speed at which insert assembly transport belt 230 is moving, such that the relative difference in speeds causes the upper insert of insert stack 320 to slide backwards, relative to the insert stack, towards and into contact with tabs 232 as the upper insert of insert stack 320 is accelerated to the same speed as insert stack 320 and insert assembly transport belt 230.
• a stationary upper belt (or portion thereof) can use friction to drag against the top surface of the upper insert of insert stack 320, thereby rear-edge registering each insert in insert stack 320 against the tabs 232.
• an optical sensor can be used to detect a leading edge of insert stack 320, tabs 232, and/or an optical marking on insert assembly transport belt 230, which indicates a position of insert stack 320 relative to one or more (e.g., each) insert feeder 30, such that, when the optical sensor is triggered, an electronic signal is sent for insert feeder 30 to deposit (e.g., eject) an insert (e.g., 322 or 324) onto insert transport plate 210 to become part of insert stack 320 or, in the case where primary insert 322 is being deposited, to be a first insert of an insert stack 320 being created.
• insert stack 320 may have only a single insert, such as primary insert 322.
• one or more of the inserts of insert stack 320 can be a pre-folded sheet of paper (e.g., bi-folded or tri-folded).
• each insert added onto insert stack 320 is dimensionally smaller in at least one dimension than the preceding insert of insert stack 320.
• one or more of the inserts of insert stack 320 can be a same size as, or even larger than, a previously deposited insert of insert stack 320.
• insert stack 320 moves along insert transport path 2 at substantially half the speed at which envelope sheet 310 moves along primary transport path 1.
• Other speed ratios between the primary and insert transport paths 1 and 2 are possible, depending on the dimensions of insert stack 320, envelope sheet 310, and/or the spacing of tabs 232 formed on or attached to insert assembly transport belt 230, which is configured to move insert stack 320 along insert transport path 2.
• the nominal speed difference of envelope sheet 310 and insert stack 320 along the primary transport path 1 and the insert transport path 2, respectively is a two-to-one ratio, wherein the transport speed of envelope sheet 310 is double the transport speed of insert stack 320.
• This speed ratio improves the reliability of the placement of insert stack 320 onto envelope sheet 310 relative to envelope fold point 366 (see, e.g., FIG. 8).
• the speed ratio improves the probability of placement of insert stack 320 on, or slightly trailing, envelope fold point 366. In such a manner, error tolerances will not accumulate to where insert stack 320 is placed in a leading position, relative to envelope fold point 366, which would result in insert stack 320 entering buckle folder system 50, causing a malfunction (e.g., a paper jam) that would require manual intervention by one or more operators.
• insert stack 320 once insert stack 320 is transported to an end of insert transport plate 210, insert stack 320 enters an insert stager 35, where an insert stack 320 is held to be deposited onto envelope sheet 310. Insert stager 35 is located within merge region 40, where insert stack 320 merges with and is deposited on top of at least a portion of envelope sheet 310.
• stager transport belts 234 accelerate insert stack 320 away from tabs 232 to prevent“sniping” of the trail edge of insert stack 320 by the rotation of tabs 232 at the transition point.
• Stager transport belts 234 are configured to be inboard and/or outboard from tabs 232.
• Stager transport belts 234 are disposed to be on top of and in contact with insert stack 320, but in some embodiments, stager transport belts can be above and/or below insert stack 320.
• Insert stack 320 passes by one or more (e.g., a plurality of) insert side jogger rollers 242, which are set at a width corresponding to a width of a widest insert sheet (e.g., the first, or control, sheet, or any subsequently deposited sheet) in insert stack 320 and vibrate insert stack 320 to facilitate the front edge justification, and also to correct conditions where the inserts (e.g., 322 and 324) in insert stack 320 may be skewed relative to one another.
• a widest insert sheet e.g., the first, or control, sheet, or any subsequently deposited sheet
• stepper motors, servo actuators, and the like are used to ensure that both side jogger rollers 242 are in/out at the same time such that the insert stack 320 is vibrated effectively, rather than merely being shifted side to side.
• a photocell may be used to determine the relative positions of the side jogger rollers at startup to ensure that their positions are sufficiently synchronized during operation.
• stager transport belt 234 is configured to accelerate insert stack 320 along stager transport plate 233, such that the inserts of insert stack 320 become forward edge registered against the stop gate 260, as shown in Fig. 4a, within the insert stager 35. Once an insert stack 320 is held within insert stager 35, insert stack 320 is held in a substantially fixed position to be deposited onto envelope sheet 310 when triggered.
• Primary transport path 1 is arranged vertically beneath insert transport path 2, such that primary transport path 1 is substantially parallel with insert transport path 2.
• insert transport path 2 may be disposed above, below, beside, adjacent to, and/or at an angle (or any combination thereof) relative to primary transport path 1.
• envelope sheet(s) 310 moves along envelope transport plate 110 of envelope conveyor 111, in direction of travel 20.
• Envelope sheet 310 is side edge registered (e.g., right or left side edge) by envelope edge justifier 114, while also being rear edge registered by envelope conveyor belt tabs 112; in some embodiments, the side edge registering occurs simultaneous with the rear edge registering in the form a push pins moving through an angled ball registration device.
• envelope edge justifier 114 can be omitted. After being side and/or rear edge registered, envelope sheet 310 moves into merge region 40, which will be discussed further in more detail for FIGS. 4A through 4G and in FIG. 5.
• the degree of precision in dispensing insert stack 320 onto envelope sheet 310 will also vary depending on the physical dimensions (e.g., size) of insert stack 320 relative to the insert region of the envelope (see, e.g., 354, FIG. 6).
• insert stack 320 is substantially a same size (e.g., within 5 mm, within 3 mm, within 2 mm, or within 1 mm) as the insert region of the envelope, it is much more critical to ensure precise dispensing of insert stack 320 onto envelope sheet 310 so that no portion of insert stack 320 extends beyond the envelope primary fold point (see, e.g., 366, FIG. 8), such that no portion of insert stack 320 is folded during formation of the mailpiece.
• insert stack 320 when insert stack 320 is significantly smaller (e.g., smaller by at least 5 mm, 10 mm, 25 mm, etc.) than the insert region of envelope sheet 310, the positioning of insert stack 320 on envelope sheet 310 need not be as precise, allowing for wider variations in placement of insert stack 320 on envelope sheet 310.
• the lateral placement of insert stack 320 on envelope sheet 310 is of similar importance to ensure that no portion of insert stack 320 is dispensed into a region where the adhesive will be dispensed, in which case, the mailpieces created will be defective.
• insert stager 35 includes a complex mechanical linkage system 280 to control an output of insert stager 35.
• Mechanical linkage system 280 includes a motor 208, a plurality of linkages, or bars, such as crank arm 201, coupler linkage 202, stop gate rocker arm 215, idler rocker arm 206, insert idler linkage arm 213, stop gate connection bar 225, and insert idler support spring 211, and a plurality of pivot points, such as coupler bearing 203, pivot bearing 216, insert idler pivot bearing 221, idler bearing 207, and stop gate pivot bearing 220, about which the respective linkages of mechanical linkage system 280 rotate.
• motor 208, crank arm 201 , and coupler linkages 202 are connected together to transfer a locomotive force from motor 208 to first and second linkage subassemblies 282 and 284, respectively.
• First and second linkage subassemblies 282 and 284 generate first and second motion profiles using the single input from motor 208, which is transmitted to the first and second linkage subassemblies 282 and 284 through pivot bearing 216, via crank arm 201 and coupler linkage 202.
• First and second motion profiles are different from each other.
• first motion profile is illustrated as stop gate travel path 262, which has a curved profile.
• Second motion profile is illustrated as insert idler roller travel path 219, which is substantially vertically oriented (e.g., having a radial component of motion as it rotates around statically fixed idler bearing 207), relative to stager transport plate 233.
• the components of mechanical linkage system 280 can be designed in any suitable fashion to produce the desired first and second motion profiles. The functionality of this mechanical linkage system 280 will be discussed in greater detail with respect to FIGS. 4E through 4G.
• insert stager 35 is configured for operation without an encoder being needed for positional detection or operation of the stager, via the mechanical linkage system 280 described herein.
• FIGS. 4A through 4D detailed side and perspective views of insert stager 35 are shown.
• insert stack generally designated 320
• Insert stack 320 has two inserts, primary insert 322 and secondary insert 324. Insert stack 320 is held in place in holding slot, generally designated 240, within insert stager 35 by stop gate 260 until insert stager 35 is triggered to deposit insert stack 320 out of insert stager 35.
• Stop gate 260 can be one piece, two pieces (or more), and has, in some embodiments, a radiused portion 260R (e.g., having a radius of about 0.5 inches) at the front face of the stop gate 260 where the insert stack impacts the stop gate during accumulation of the inserts 322 and 324.
• Insert stack 320 is now front registered within holding slot 240, such that the leading edge of each insert sheet of insert stack 320 (e.g., both primary insert 322 and secondary insert 324) are both adjacent to and/or in direct contact with stop gate 260.
• insert stager 35 is actually inclined with respect to gravity, such that both primary insert 322 and secondary insert 324 are front edge registered against stop gate 260.
• Insert stack 320 is also held between insert guide plate 235 and stager transport plate 233.
• primary insert 322, secondary insert 324, stager transport plate 233, and insert guide plate 235 are shown being physically separated from each other to provide added clarity of the view shown, but these elements will, at various points in time during normal operation, come into contact with one or more of these other structures. Cyclic movement of the components of the insert stager 35 are accomplished via translation of a single input (e.g., a rotary force output from motor 208) to drive distinctly different motion profiles of stop gate 260 and insert idler roller 204, respectively, via a complex mechanical linkage system 280 (see FIGS. 4E through 4G).
• a single input e.g., a rotary force output from motor 208
• a complex mechanical linkage system 280 see FIGS. 4E through 4G.
• This arrangement allows for a repeatable cyclic motion profile (e.g., a smooth sinusoidal motion), with a controlled motion profile at impact to allow for quieter operation, less impact force, less wear on components, less damage to mailpieces, and increased reliability of insert stager 35.
• the insert idler roller 204 moves sinusoidally over a controlled path, gradually increasing force (e.g., having an analog characteristic) on insert stack 320, while stop gate 260 also moves over a defined path without sudden (e.g., impulsive) motion.
• An example motion path for the mechanical linkage system 280 is shown in FIGS. 4E through 4G, which will be described in greater detail below.
• Stager transport belts accelerate inserts 322, 324 away from tabs 232 to prevent sniping of the rear edges thereof by tabs 232, then slows inserts 322, 324 to maintain an effectively constant speed along insert transport path 2, so that each insert stack 320 moves the same distance for every cycle of the machine.
• programmable motors and/or one or more variable cam mechanisms can be used to produce a repeatable variability of the speed of insert stack 320.
• Inserts 322 and 324 are released from the friction belts after having traversed approximately half of the length of stager transport plate 233. Inserts 322, 324 then traverse the remainder of the length of stager transport plate 233, into holding slot 240, by momentum and the vibration created by insert side jogger rollers 242. This method results in a very gentle impact into the stop gate 260, hence no damage to the leading edges of inserts 322, 324 from striking stop gate 260.
• Stop gate travel path 262 facilitates the smooth ejection of insert stack 320 from holding slot 240 onto envelope conveyor 111 by moving away from insert stack 320 as insert idler roller 204 engages against insert stack 320 and compresses insert stack 320 against insert drive roller 205.
• Variations in insert stack 320 ejection onto envelope conveyor 111 are a function of the frictional characteristics of the paper from which insert stack 320 is made, and the looseness of insert stack 320 within holding slot 240. These variations in the ejection process, are accommodated by stop gate travel path 262, further reducing the possibility of damage to the leading edges of inserts 322, 324
• insert stager 35 operates through use of a complex mechanical linkage system, generally designated 280, that is commonly driven by a single locomotive source. While the complex mechanical linkage system 280 of insert stager 35 is advantageous for the reasons noted hereinabove, in other embodiments, mechanical linkage system 280 can be replaced with any other suitable combination of mechanical linkage(s), as will be understood by those having ordinary skill in the art and, furthermore, may include two separately driven mechanical linkage systems.
• Non-limiting examples of such other possible mechanical linkages include pneumatic actuators, which suffer from a lack of feedback control, electromagnetic actuators, which generally require the use of mechanical snubbers/dampers to soften the impulsive nature of the impact (e.g., the driven motion), and a servo motor to control motion, e.g., a linear motion controlled servo-driven actuator, which suffers from excessive cost.
• a locomotive force is transmitted, here in a rotary fashion, from motor 208 into a crank arm 201, which is fixedly connected to a first (e.g., proximal) end of a coupler linkage 202 via a coupler bearing 203, which rotatably attaches coupler linkage 202 to crank arm 201.
• Coupler linkage 202 simultaneously transmits the rotary movement of crank arm 201 to idler rocker arm 206 and stop gate rocker arm 215, both of which are connected at their first (e.g., proximal) ends to the second (e.g., distal) end of coupler linkage 202 at pivot bearing 216.
• a slot is formed through the thickness of insert guide plate 235 at least in a position vertically underneath insert idler rollers 204, such that insert idler rollers 204 can move substantially vertically to press insert stack 320 against one or more (e.g., two) insert drive rollers 205 for ejection of insert stack 320 from insert stager 35.
• insert idler rollers are shown herein being disposed such that substantially all of insert drive rollers 205 are disposed beneath stager transport plate 233, with only a portion of insert drive rollers 205 protruding beyond the upper surface of stager transport plate 233 and into holding slot 240.
• insert idler rollers 204 pass beyond the bottom surface of insert guide plate 235, into holding slot 240, to contact an upper surface of insert stack 320 (e.g., an upper surface of secondary insert 324), thus compressively“sandwiching” insert stack 320 between insert idler rollers 204 and insert drive rollers 205 so that insert drive rollers 205 impart a driving ejection force to insert stack 320.
• insert stack 320 e.g., an upper surface of secondary insert 324
• Stop gate connection bar 225 is rotatably movable around, at a first (e.g., proximal) end thereof, stop gate pivot bearing 220, and is either fixedly attached to (e.g., by compression, such as a screw and nut arrangement) or integrally formed as part of (e.g., in a single piece with) stop gate rocker arm 220 at a second (e.g., distal) end thereof.
• Stop gate 260 is attached to and/or integrally formed as a single piece with stop gate connection bar 225.
• stop gate rocker arm 215, stop gate connection bar 225, and stop gate 260 form a single unitary structure (e.g., are integral, monolithic, and/or formed as a single piece).
• stop gate rocker arm 215, stop gate connection bar 225, and stop gate 260 are formed integrally with one or more of the other structures.
• each of stop gate rocker arm 215, stop gate connection bar 225, and stop gate 260 are formed discretely from each other and are substantially rigidly attached to each other in the manner described above.
• crank arm 201 along motor direction 209 also drives an oscillatory substantially vertically downward movement (e.g., having a radial component as it rotates around idler bearing 207) of insert idler rollers 204, through a second linkage subassembly, generally designated 284, along a second motion profile defined by insert idler roller travel path 219.
• first linkage subassembly 282 is configured, via its connection to coupler linkage 202 at pivot bearing 216, to receive the single input from motor 208 through crank arm 201 , coupler bearing 203, coupler linkage 202.
• First linkage subassembly 282, in the embodiment shown, includes stop gate rocker arm 215, stop gate pivot bearing 220, stop gate connection bar(s) 225, and stop gate 260. Components may be added, modified, and/or omitted to achieve any of a plurality of desired motion profile outputs, as will be understood by those having ordinary skill in the art.
• Stop gate rocker arm 215 is rotatably connected at a first end thereof to coupler linkage 202 at pivot bearing 216; as such, stop gate rocker arm 215 is configured to be driven, via coupler linkage 202 and pivot bearing 216, through the stop gate rocker arm travel paths 217, which varies according to a stage of actuation of mechanical linkage system 280, three positions respectively being illustrated in FIGS. 4E, 4F, and 4G. Stop gate rocker arm 215 is rotatably (e.g., pivotably) connected at its second end to stop gate pivot bearing 220, which is spatially fixed (e.g., incapable of translatory movement during operation).
• stop gate pivot bearing 220 is statically fixed (e.g., allows only rotary motion thereabout)
• stop gate rocker arm travel path 217 has a shape of an arc, as stop gate rocker arm 215 is only capable of rotary motion about stop gate pivot bearing 220.
• One or more stop gate connection bars 225 are each rigidly connected at the respective first ends thereof to stop gate rocker arm 215, such that the rotary motion of stop gate rocker arm 215 around stop gate pivot bearing 220 causes a corresponding (e.g., identical) angular rotation of the one or more stop gate connection bars 225 around stop gate pivot bearing 220.
• the one or more stop gate connection bars 225 and/or the stop gate rocker arm 215 may be connected to an intermediate structure that itself is fixed to (e.g., allowing rotary motion about) stop gate pivot bearing 220.
• Stop gate 260 is connected to (e.g., integrally or removably) a second end of the one or more stop gate connection bars 225 and is arranged at an angle relative to a main portion of the one or more stop gate connection bars 225, so that stop gate 260 can be arranged substantially orthogonal to (e.g., within 15°, within 10°, within 5°, within 2°, or within 1 °) the plane defined by stager transport plate (see, e.g., 233, FIG. 4C) while the one or more stop gate connection bars 225 are arranged at a second, non-orthogonal, angle.
• second linkage subassembly 284 is configured, via its connection to coupler linkage 202 at pivot bearing 216, to receive the single input from motor 208 through crank arm 201 , coupler bearing 203, coupler linkage 202.
• Second linkage subassembly 284 in the embodiment shown, includes idler rocker arm 206, insert idler pivot bearing 221, insert idler linkage arm 213, insert idler roller 204, insert idler roller support spring 211 , and idler pivot 207.
• Components may be added, modified, and/or omitted to achieve any of a plurality of desired motion profile outputs, as will be understood by those having ordinary skill in the art.
• Idler rocker arm 206 is rotatably connected at a first end thereof to coupler linkage 202 at pivot bearing 216; as such, idler rocker arm 206 is configured to be driven, via coupler linkage 202 and pivot bearing 216, through the idler rocker arm travel path 218, which has rotary and translatory components and the particular directions of which vary according to a stage of actuation of mechanical linkage system 280, three positions respectively being illustrated in FIGS. 4E, 4F, and 4G.
• Idler rocker arm 206 is rotatably (e.g., pivotably) connected at its second end to insert idler linkage arm 213 at insert idler pivot bearing 221.
• insert idler linkage arm 213 is generally“L” shaped and is a rigid structure that will not deform (e.g., will only elastically deform, without yielding in plastic deformation) during normal use. Insert idler linkage arm 213 and idler rocker arm 206 are able to rotate relative to each other at insert idler pivot bearing 221. As coupler linkage 202 drives idler rocker arm 206 downwards and in a counterclockwise direction, insert idler linkage arm 213 rotates in the same counterclockwise direction around idler pivot 207, which is rigidly fixed to the insert stager (e.g., at a housing thereof).
• Insert idler roller 204 is rotatably connected to insert idler linkage arm 203 and is positioned such that, as insert idler linkage arm 203 rotates in the counterclockwise direction about idler pivot 207, insert idler roller(s) 204 will be substantially vertically aligned on top of (e.g., sufficiently to impart the compressive force to reliably dispense the insert stack from the insert stager, as those having ordinary skill in the art will appreciate) insert drive roller(s) 205.
• Insert idler roller support spring 211 provides a spring force to insert idler linkage arm 213 that is in the same counterclockwise direction with respect to idler pivot 207, in order to prevent bounding or stuttering of insert idler roller(s) 204 vertically away from insert drive roller(s) 205 as insert idler roller(s) 204 is driven downwards to apply the compressive force to the insert stack be engaging with insert drive roller(s) 205.
• a single input is used to produce two distinct motion profiles that are synchronized (e.g., simultaneous) with each other, each of the single input, the first motion profile, and the second motion profile having different aspects of motion.
• crank arm 201 rotates along motor direction 209 to a second position, which is substantially diametrically opposite to the position shown in FIG. 4E.
• An intermediate position between the first and second positions is shown in FIG. 4F. While motor direction 209 is shown in a counter-clockwise direction, crank arm 201 can be rotated in either clockwise or counterclockwise directions by motor 208
• crank arm 201 moves from the first position in FIG. 4E towards the second position, passing through the intermediate position shown in FIG. 4F, the mechanical linkage system is driven to produce a movement of idler rocker arm 206, which has both rotational and linear aspects along idler rocker arm travel path 218, as shown in FIG. 4E.
• stop gate rocker arm 215 pivots radially about stop gate pivot bearing 220, causing a corresponding (e.g., proportional) rotational movement of stop gate connection bar 225 and stop gate 260, generally along stop gate travel path 262, to the second position of stop gate 260.
• stop gate 260 is actuated to the second (e.g., open) position while insert stack 320 is compressively engaged between insert drive rollers 205 and insert idler rollers 204, resulting in imparting the rotary drive force of insert drive roller 205 to insert stack 320, causing the ejection of insert stack 320 out of insert stager 35 while stop gate 260 is in the second (e.g., open) position.
• Insert idler roller support spring 211 design parameters are selected to prevent the insert idler 204 from bouncing upon impact with the top side of insert stack 320. Selecting too weak of a spring force will result in the insert idler roller 204 bouncing upon contact, which can prevent the continuous ejection of insert stack 320 from insert stager 35, as the ejection force transmitted to insert stack 320 by insert drive roller 205 will be intermittently decoupled from insert stack 320 when insert idler roller 204 bounces away from insert drive roller 205. Selecting an insert idler roller support spring 211 that is too strong can cause a binding action, which can prevent the continuous ejection of insert stack 320 from insert stager 35.
• insert stack 320 may not be positioned correctly on envelope sheet 310 after ejection of insert stack 320 from insert stager 35, resulting in a system malfunction (e.g., a paper jam) or defective mailpiece.
• a system malfunction e.g., a paper jam
• FIG. 4E shows a first position of the components of the mechanical linkage system, such that insert idler roller 204 is spaced apart from insert drive roller 205 and stop gate 260 is in a closed position.
• motor 208 drives the crank arm 201 in the direction of motor direction 209 to the position shown in FIG. 4F.
• insert idler roller 204 is in contact with insert drive roller 205 to impart the rotational driven motion of insert drive roller 205 to an insert stack, while stop gate 260 is in an open position to allow the dispensing of an insert stack from insert stager.
• motor 208 is driven in the direction of motor direction 209, as indicated in FIG. 4F.
• This further motion moves through the second (e.g., fully extended) positions of the mechanical linkage system, such that, as the mechanical linkage system is driven from the position shown in FIG. 4F to the position shown in FIG. 4G, stop gate rocker arm 215 initially moves in the direction indicated by stop gate rocker arm path 217A, before reversing the direction of travel along stop gate rocker arm path 217B.
• This movement is also reflected in the movement of stop gate 260, which initially is driven in the direction of stop gate travel path 262A, before reversing the direction of travel of stop gate 260, as indicated by stop gate travel path 262B.
• insert idler roller 204 is already in contact with insert drive roller 205, the movement of coupler linkage does not cause any substantial further movement of insert idler roller 204, but instead this motion is accommodated by additional bending of insert idler support spring 211 relative to idler rocker arm 206 and insert idler linkage arm 213 at insert idler pivot bearing 221.
• FIG. 4G shows a second intermediate position of the components of mechanical linkage system, such that insert idler roller 204 is separated from insert drive roller 205 and, as crank arm 201 is rotated in the direction of motor direction 209, insert idler roller 204 moves substantially vertically away from (e.g., having a radial component as it rotates around idler bearing 207) insert drive roller 205, this substantially vertical movement being indicated by insert idler roller travel path 219, while idler rocker arm 206 moves and/or rotates in the directions indicated by idler rocker arm travel path 218.
• stop gate rocker arm 215 rotates in the direction of stop gate rocker arm path 217, which causes a corresponding (e.g., proportional) rotation of stop gate 260 in the direction indicated by stop gate travel path 262.
• the mechanical linkage system will be in (e.g., pass through) substantially the first position illustrated in FIG. 1.
• Stop gate optical sensor 259 is configured to detect when insert stack 320 is no longer present and to send an electronic signal that initiates a rotary movement of crank arm 201 to the first position, as shown in FIGS. 4A through 4D, such that one or more (e.g., two) insert idler rollers 204 vertically move away from one or more (e.g., two) insert drive rollers 205, and stop gate 260 rotates back to the first (e.g., closed) position shown in FIGS. 4A through 4D.
• Crank arm 201 can be configured to rotate about a full 360° or can be configured to rotate only over substantially half (e.g., approximately 180°) of a circular revolution in moving between the first and second positions.
• stop gate 260 moves radially along stop gate travel path 262, as is controlled by the rotary movement of crank arm 201, via a travel of stop gate rocker arm 215 along stop gate rocker arm path 217, which is shown as pivoting radially around stop gate pivot bearing 220.
• Stop gate 260 is shown in its first position in FIGS. 4A through 4D, while the second position of stop gate lies at the opposite end of stop gate travel path 262 (see, e.g., other end of double arrow in FIGS. 4A and 4C).
• idler rocker arm 206 and stop gate rocker arm 215 are connected to coupler linkage 202 at a single pivotable connection point (e.g., pivot bearing 216), idler rocker arm 206 moves at substantially a same frequency as the stop gate rocker arm 215, such that idler rollers 204 are not engaged against drive rollers 205 (e.g., are in their first position) when stop gate 260 is in the position (e.g., the first position) shown in FIG. 4C.
• the complex motion described hereinabove can be, in some embodiments, accomplished by a single revolution e.g., around substantially 360°) of motor 208, thus reducing the control complexity needed for motor 208.
• motor 208 can be controlled to rotate reciprocally (e.g., back-and-forth) through less than a full revolution, such as, for example, approximately 180°.
• an insert stack 320 is disposed within insert stager 35, prepared for ejection onto envelope sheet 310, which is moving in direction of travel 20 along envelope transport plate 110.
• envelope sheet 310 is in the dispensing position, generally designated 314, and, in this position, envelope sheet 310 is detected by merge optical sensor 264, which triggers insert stager 35 to eject insert stack 320 from insert stager 35, as described above in the description of FIG. 5.
• Merge drive roller 250 is omitted from this view for clarity.
• Envelope sheet 310 is continuously moved at a substantially constant speed as insert stack 320 is ejected from insert stager 35 and deposited on top of envelope sheet 310.
• a computer (e.g., 100, FIG. 1 ) is configured to use the operational parameters, such as, for example, envelope sheet transport speed, signal latency of merge optical sensor 264, the dimensions (e.g., length and/or width) of envelope sheet 310, and/or the dimensions (e.g., length and/or width) of insert stack 320 to determine a precise timing setting for ejection of insert stack 320, measured from the moment that merge optical sensor detects the leading edge 360 of envelope sheet 310, such that insert stacks 320 are precisely and accurately deposited onto a designated area of envelope sheets 310.
• the operational parameters such as, for example, envelope sheet transport speed, signal latency of merge optical sensor 264, the dimensions (e.g., length and/or width) of envelope sheet 310, and/or the dimensions (e.g., length and/or width) of insert stack 320 to determine a precise timing setting for ejection of insert stack 320, measured from the moment that merge optical sensor detects the leading edge 360 of envelope sheet 310, such
• the timing for the delay between detection of the leading edge 360 of envelope sheet 310 and the ejection of insert stack 320 from insert stager 35 can be manually controlled, at least partially, by an operator.
• a computer sets an initial timing delay value based on one or more of the operational parameters noted above, and an operator is capable of fine-tuning (e.g., changing) this initial timing delay value based on performance of system 10.
• envelope sheet 310 and insert stack 320 have been merged and the leading edge 360 of envelope sheet 310 is continuing to move at a substantially constant speed along envelope transport plate 110, entering adhesive application region 45.
• insert stager 35 has been omitted from this view.
• an adhesive e.g., a pressure-sensitive bonding glue
• Waste adhesive reservoirs 148 are disposed underneath each adhesive applicator 140, to catch any excess adhesive that might otherwise be transferred to other portions of system 10, causing defective mailpieces.
• insert stack 320 is positioned on envelope sheet 310 so as to define, on one side of insert stack 320, a flap region 350, and, on a second side of insert stack 320, a back region 352. While it is contemplated that actual lines or creases may be formed on envelope sheet 310 along the broken lines defining flap region 350 and back region 352, in the embodiment shown, the broken lines are phantom lines that are not in any way physically represented on envelope sheet 310. As will be discussed further regarding other figures, the back of a finished mailpiece will be formed from the portion of envelope sheet 310 within back region 352, while the flap of a finished mailpiece will be formed from the portion of envelope sheet 310 within flap region 350.
• envelope sheet 310 will be engaged by and/or between a plurality of transport rollers 121.
• the plurality of transport rollers 121 are configured to move envelope sheet 310 and insert sheet 320 at the same speed at which envelope sheet 310 moves in, for example, merge region (e.g., 40, FIG. 3).
• the transport rollers 121 may be configured to move envelope sheet 310 at a slower or faster speed (e.g., to decelerate and/or accelerate envelope sheet 310) than an entry speed of envelope sheet 310 into transport rollers 121.
• envelope sheet 310 and insert stack 320 are compressively engaged between opposing transport rollers 121 on top and bottom sides of envelope sheet 310 and insert stack 320.
• each of the plurality of transport rollers 121 is driven by transport roller drive motor 120.
• one or more of the sets of a plurality of rollers 121A, 121B, 121C may have only a single transport roller 121 and/or may be omitted entirely.
• Each of the sets of a plurality of transport rollers 121 A, 121 B, 121C may be controlled independently or by a single motor.
• each transport roller 121 rotates at substantially the same speed as each other transport roller 121.
• each of the plurality of transport rollers 121 and each of the plurality of adhesive sealing rollers 150 are drive by a roller drive belt 122.
• a plurality of such roller drive belts 122 may be provided.
• the signal from diverter optical sensor 126 is transmitted directly to the fold diverter motor. In other embodiments, the signal from diverter optical sensor 126 is transmitted to computer 100, which can apply further operational parameters (e.g., a delay, a duration of actuation, a height of actuation, etc.) to the signal, and then transmit the signal to the fold diverter motor.
• further operational parameters e.g., a delay, a duration of actuation, a height of actuation, etc.
• computer 100 or PLC components can instruct adhesive applicators 140 to not dispense any adhesive (or withhold instructions to apply the adhesive) and, furthermore, keep the fold diverter 130 in the rest (e.g., non-actuated) position so that any envelope sheet 310 that arrives outside of the anticipated time period window will not be diverted onto fold plate 160, but will instead be minimally processed and output, either to be discarded to fed through system 10 again.
• adhesive applicators 140 can instruct adhesive applicators 140 to not dispense any adhesive (or withhold instructions to apply the adhesive) and, furthermore, keep the fold diverter 130 in the rest (e.g., non-actuated) position so that any envelope sheet 310 that arrives outside of the anticipated time period window will not be diverted onto fold plate 160, but will instead be minimally processed and output, either to be discarded to fed through system 10 again.
• Envelope sheet 310 is driven vertically up fold plate 160 at the constant speed at which envelope sheet 310 is propelled by transport rollers 121.
• the transport speed at which envelope sheet 310 is moved by transport rollers 121 is used, such that an actuation time for fold diverter 130 is set, fold diverter 130 returning to the first position after the actuation time elapses.
• an optical sensor is used to detect envelope sheet moving vertically up fold plate 160 in order to move fold diverter 130 back to the first position; in some embodiments, this optical sensor can be used to disable adhesive applicators 140 when the lead edge of envelope sheet 310 is not detected.
• a vertical position of fold plate stop bar 162 is selected based on the dimensions of envelope sheet and the size of the mailpiece to be created.
• fold plate stop bar adjuster 164 can include a knurled knob threadably engaged on a rod captively passing through a fold plate stop bar slot 166.
• detents can be formed in fold plate stop bar slot 166 in order to define preset vertical positions of fold plate stop bar 162, these preset vertical positions corresponding to preset sizes of envelope sheets 310 to be processed.
• envelope sheet 310 and insert stack 320 are both shown being engaged (e.g., compressively) between transport rollers 121 as envelope sheet 310 and insert stack 320 are driven by transport rollers at constant velocity.
• fold diverter 130 has returned to the first, unactuated, position, such that, after leading edge 360 of envelope sheet 310 contacts fold plate stop bar 162, preventing any further vertical movement along this vertical buckle path, envelope sheet 310 is driven underneath fold plate 160. Because the vertical movement of envelope sheet 310 is stopped by fold plate stop bar 162, but envelope sheet 310 is still being driven at constant velocity by transport rollers 121, envelope sheet 310 is folded over itself at envelope primary fold point 366, defining back region 352 above this point. As is shown in FIG.
• first and second sets of transport rollers 121 A and 121 B continue to drive envelope sheet underneath fold plate 160, thus driving envelope primary fold point 366 to be engaged between third set of transport rollers 121C.
• the speed of envelope sheet 310 and insert sheet 320 are substantially unchanged as envelope primary fold point 366 is defined and insert region of the envelope (see, e.g., 354, FIG. 6) is substantially coplanar with the inserts within insert stack 320..
• first adhesive optical sensor 128 is triggered by leading edge 360 of envelope sheet 310
• adhesive is applied by adhesive applicators 140 adjacent to and/or substantially at the lateral edges of envelope sheet 310.
• the adhesive is, in some embodiments, a pressure-sensitive liquid dispensed glue. In some other embodiments, the adhesive may be dispensed as a gel or as a film, rather than a liquid.
• Adhesive is applied to envelope sheet 310 at adhesive application point 146, starting at adhesive start point 142 along adhesive line 144.
• a delay time value may be programmed in order for envelope sheet 310 to move beyond the detection point at which leading edge 360 is detected by first adhesive optical sensor 128, such that the adhesive is not applied prematurely.
• the duration of adhesive application is set by a timer value based, for example, on the size of envelope sheet 310 and the speed at which transport rollers 121 are operated.
• envelope sheet enters side adhesive sealer, generally designated 55.
• side adhesive sealer portions of envelope sheet are sealed to each other, such that a partially assembled envelope, generally designated 400, is formed by pressure sealing of back of envelope 420 to front of envelope 410 between adhesive sealing rollers 150.
• the adhesive can be applied in a pattern comprising a solid line, dots, and/or dashes, the latter of which can be beneficial in minimizing adhesive consumption.
• envelope 400 is pushed along by transport rollers 121 into adhesive sealing rollers 150.
• adhesive sealing rollers 150 may be driven at the same speed as transport rollers 121.
• adhesive sealing rollers 150 are configured as idler rollers.
• adhesive sealing rollers 150 and transport rollers 121 are made of an elastomeric material, such as silicone, rubber, or latex. In some other embodiments, adhesive sealing rollers 150 are made from a material having a higher or lower durometer than transport rollers 121, thus providing for an enhanced seal formed by the adhesive. In some embodiments, adhesive sealing rollers 150 and the axles associated therewith are separate from (e.g., physically isolated from) the axles of transport rollers 121 , so that the thickness of insert stack 320 does not affect the pressure applied by adhesive sealing rollers 150.
• adhesive sealing rollers 150 being arranged laterally outside of the width of the widest insert within insert stack 320, such that transport rollers 121 will be vertically displaced by the thickness of insert stack 320 as it moves therethrough, without any accompanying vertical displacement of adhesive sealing rollers 150 associated therewith.
• adhesive sealing rollers 150 are arranged laterally outside of transport rollers 121, so that only envelope sheet 310 and the adhesive are compressed between adhesive sealing rollers 150, so that a constant pressure is applied to seal the adhesive, independent of a thickness of insert stack 320.
• RAT module 60 includes one or more (e.g., two) right angle turn assemblies 170, which include a plurality of rollers that alter a directional path of envelope 400 by such that, after envelope 400 moves underneath right angle turn assemblies 170, the direction of travel 20 of envelope 400 is substantially orthogonal compared to the direction of travel 20 before envelope 400 entered the right angle turn assemblies 170. Any suitable RAT module 60 may be used, including those that will physically rotate envelope 400 without altering a travel direction thereof.
• envelope 400 is bottom edge registered by one or more bottom edge justifier assemblies 172 and the movement of envelope 400 is aided by one or more envelope guides 174.
• An envelope side adjuster 176 can be used to adjust a behavior of the bottom edge justifier assemblies 172 and/or a position of one or more of the envelope guides 174.
• envelope 400 is transferred into flap creaser region 70, where movement of envelope is controlled by a plurality of spring-loaded rollers 183 that are aligned vertically over plow fold guide 184.
• plow fold guide is one or more driven belts that move underneath envelope 400.
• rollers 183 are not spring-loaded, but are held in place by gravity.
• one or more of rollers 183 is driven to apply a locomotive force to envelopes 400.
• Envelope 400 has a crease formed therein at a location above which envelope flap 430 (see, e.g., FIG. 10) is to be formed.
• Envelope 400 is driven and/or pulled in between grooved crease roller 180 and peaked crease roller 181 to for the crease. Crease rollers 180 and 181 can be driven or idler rollers.
• envelope 400 enters flap adhesive applicator region 75, which can be immediately adjacent to crease rollers 180 and 181.
• flap adhesive applicator region an optical photo sensor 185 is triggered and flap adhesive applicator dispenses an adhesive onto envelope flap 430 above the crease line defining envelope flap 430.
• the adhesive dispensed can be either the same or a different adhesive as was shown and described relative to FIG. 8.
• envelope 400 enters flap plow folder region 85 and engages within and/or around plow folder 186.
• envelope flap 430 is pressed and sealed against envelope front 410 by flap sealer 188 in flap sealer region 85. After being sealed (e.g., compressively between rollers), envelope 400 is deposited into output region 90 for transport and delivery by a designated postal service carrier.

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